Inorganic nano-materials produced by the thermal treatment of metal-infused organic polymers

ABSTRACT

A method of forming an inorganic nano-material by thermally treating metal-infused organic polymers to remove the organics to leave an inorganic nano-material where the metal-infused organic polymer precursor may be formed by a polymer synthesis reaction of organic monomers with a metal-containing precursor and by combining a metal containing precursor with at least one organic monomer to obtain a mixture and initiating a polymerization reaction of the mixture to form a metal-infused organic polymer precursor.

TECHNICAL FIELD

This disclosure generally relates to syntheses of inorganicnano-materials produced by the thermal treatment of metal-infusedorganic polymers.

BACKGROUND

Inorganic nano-materials are of broad interest to a number of industriesfor many applications such as energy storage, energy production, scratchresistant coatings, air scrubbing, drug delivery and hydrophobicmaterials to name a few. Typical syntheses of these materials requireexpensive techniques and/or environmentally harmful reagents with amultitude of time-consuming steps, often making these processesimpractical for commercial production and scaling.

In the interest of producing cost effective, less harmfulenvironmentally and scalable inorganic nano-materials with cheapreagents and few processing steps, the necessity arose to developembodiments of this disclosure.

BRIEF EXPLANATIONS OF THE DRAWINGS

FIG. 1 is a simplified diagram of a synthetic method of producinginorganic nano-materials by thermally treating metal-infused organicpolymers according to an embodiment of the present invention.

FIG. 2A is a close-up scanning electron microscope (SEM) image ofnano-LiMn₂O₄ produced by the thermal treatment of a Mn and Li infusedorganic polymer according to an embodiment of the present invention.

FIG. 2B is a zoomed out scanning electron microscope (SEM) image ofnano-LiMn₂O₄ produced by the thermal treatment of a Mn and Li infusedorganic polymer according to an embodiment of the present invention.

FIG. 3 is a flow diagram illustrating several methods of producinginorganic nano-materials according to various embodiments.

DETAILED DESCRIPTION

In this disclosure, the inorganic nano-material synthesis is streamlinedand avoids numerous processing stages that would be unfavorable toscale-up and avoids use of environmentally harmful and expensivereagents. Unlike other nano-material syntheses which require 3 or moresteps to fabricate the final product, the method described herein mayinclude only two primary steps (See FIG. 1 and algorithm 30 shown inFIG. 3 ):

-   1) A polymer synthesis reaction of organic monomers with    metal-containing precursor to produce a metal-infused organic    polymer precursor (activity 32 of algorithm 30 shown in FIG. 3 );    and-   2) Thermal removal of the organic portion of the precursor to    produce an inorganic nano-material (activity 34 of algorithm 30    shown in FIG. 3 )

As shown in FIG. 1 and FIG. 3 , an activity 32 of an embodiment 10involves the synthesis of one or more organic monomers 12 capable ofreacting to form a polymer (covalently bonded structural units) in thesame reaction flask 16 as one or more metal-containing precursors 14. Inan embodiment where this synthesis produces fine nanostructures, themetal-containing precursor 14 may be somewhat soluble in one of thephases in the polymer formation reaction. In some embodiments of thisalgorithm 30, the metal-containing precursors 14 may contain an alkalimetal, alkaline earth metal, transition metal, post-transition metal,metalloid, lanthanide, and/or actinide in the form of either pure metal,oxide, chalcogenide, nitride, and/or a metal salt such as nitrate,hydroxide, carbonate, acetate, halide or other.

In an embodiment an inorganic nano-material 18 is formed by combiningone or more metal containing precursors 14 with one or more organicmonomers 12 to obtain a mixture. Then a polymerization reaction of themixture may be initiated to form an interconnected polymer/metal-ionmatrix. The resultant matrix may be calcinated to remove organics 17 andform an inorganic nano-material 18. In an embodiment, the organicmonomer may contain one or more π-bonds including but not limited to:carbon-carbon, carbon-oxygen, carbon-nitrogen, nitrogen-nitrogen. In anembodiment, the polymerization reaction initiation may include radical,anionic, and cationic polymerization. In an embodiment, the metal ion inthe metal containing salt may be an alkali metal, alkaline earth metal,transition metal, post-transition metal, metalloid, lanthanide, oractinide.

In an embodiment, the resulting polymer is coordinated to themetal-ions. In an embodiment, the polymer/metal-ion matrix may be heatedto a range between about 300° C. to about 800° C. at a rate of about 1°C. per hour to about 500° C. per hour and kept at said temperature forup to 48 hours. In an embodiment, the heating of the polymer/metal-ionmatrix includes crystallization of the resulting inorganicnano-material. In an embodiment, the inorganic nano-material may be usedin an electrode for a lithium ion battery. In an embodiment, theinorganic nano-material may be used in a cathode for a lithium ionbattery, catalyst or other device. In an embodiment, the inorganicnano-material may be used in a device or fabrication.

In some embodiments, the organic monomers 12 contain one or more π-bonds(including but not limited to carbon-carbon, carbon-oxygen,carbon-nitrogen, nitrogen-nitrogen) and/or epoxides capable ofpolymerizing via radical, anionic, cationic or other polymerizationsmechanisms.

In some embodiments, the polymerization reaction may be initiated by acatalyst, whereas in other embodiments it may be initiated by heat,agitation or other polymerization stimulating effects.

In some embodiments, “metal-infused organic polymer” refers to anorganic polymer which has metal atoms coordinated to its functionalgroups. In other embodiments, “metal-infused organic polymer” refers toan organic polymer which has metal atoms trapped within the polymermatrix.

In an embodiment as shown in FIG. 1 and FIG. 3 , an activity 34 of anembodiment 10, may include the removal of the organic portion of theprecursor may be performed by heating up the metal-infused organicpolymer precursor to a temperature of 350 to 750° C. and about 550 to750° C. In an embodiment, the metal-infused organic polymer precursormay be soaked for up to 24 hours and about 10 hours. In an embodiment,heating 19 the metal-infused organic polymer precursor to temperaturesof 350 to 750° C. and about 550-750° C. results in the simultaneousorganic removal and inorganic fusion which leads to an inorganicnano-material end-result 18.

In some embodiments, an activity may include the evaporation of excesssolvent between the two activities 32, 34 listed above by heating and/orpulling vacuum on the metal-infused organic polymer precursor in orderto prevent excess swelling and/or unwanted side reactions. In a typicalprocedure, evaporation at a temperature just below the boiling point ofa solution may be used while stirring in air and then once condensed maybe transferred to a heat resistant substrate (stainless steel, fusedquartz, etc.) and heated under vacuum at just below the boiling point ofthe solvent. In an embodiment, a common solvent that may be used iswater which may be removed by heating the metal-infused organic polymerprecursor in an oil bath at 95° C. for about 2-4 hours followed bytransfer to a steel or fused quartz substrate and heated at 95° C. undervacuum for an additional 2+ hours.

Inorganic nanomaterials produced from these various methods may includemorphologically interconnected nodes or globules with free space betweenthe nodes or globules. In some embodiments the resulting nano-materialsmay have crystallite sizes between 5 to 100 nm and about 5-40 nmdetermined by the Scherrer width acquired from X-ray diffraction (XRD)data. In some embodiments, the resulting particle size has been observedto be between 10 nm to 300 nm and about 10 nm to about 100 nm byscanning electron microscopy (SEM).

Some embodiments relate to a method for producing an inexpensive, andscalable nano-materials for use as the active materials in lithium ionbatteries. In another embodiment, the resulting nano-material may beused as a high surface area heterogeneous catalyst. In otherembodiments, the resultant nano-material may be used an air-scrubbingand/or liquid-purifying nano-material, such as for capture of largeparticles, carbon dioxide or other air or liquid-born molecules. Itshould be noted that in an embodiment the use of nano-materials producedfrom these various methods is not limited to those stated above butincludes a multitude of products and uses not listed.

When a nano-material produced from this synthesis is used as an activematerial in a lithium ion battery, it can be directly substituted foreither the anode or cathode (depending on the composition) material in aslurry which is then typically cast on conductive foil for use as anelectrode in a lithium ion battery. When paired with another electrodematerial in a lithium ion cell, the resulting battery can be capable ofextremely fast charging in the range of several minutes with highcycling life times when paired with another electrode material ofequivalent kinetic and cycling advancement.

The embodiments described herein are provided to illustrate and providea detailed description for those of ordinary skill in the art. Theembodiments should not be construed as limiting, as the embodimentsmerely provide one of many methodologies.

In an embodiment, an inorganic nano-material used for variousapplications may be produced via synthesis according to various methods.To produce such an inorganic nano-material according to an embodiment,an amount of one or more metal-containing precursors 14 containing analkali metal, alkaline earth metal, transition metal, post-transitionmetal, metalloid, lanthanide, and/or actinide in the form of either puremetals, oxides, chalcogenides, nitrides, and/or metal salts such asnitrates, hydroxides, carbonates, acetates, halides or others in someembodiments is combined with one or more organic monomers 12 containingone or more π-bonds (including but not limited to carbon-carbon,carbon-oxygen, carbon-nitrogen, nitrogen-nitrogen) and/or epoxidescapable of polymerizing via radical, anionic, cationic or otherpolymerizations mechanisms in some embodiments in glassware 16 such as around bottom flask or other heating vessel of glass or a differentmaterial that may include a condenser in some embodiments.

In some embodiments, an amount of an organic surfactant is added to thesolution and in some embodiments a solvent such as water, ethanol orother solvent is also added to the solution. In an embodiment, the pH ofthe solution is controlled by addition of any number of buffers such asammonia, tartaric acid, acetate or other. In some embodiments, theresulting solution is then either heated, stirred or agitated at lowheat typically below the boiling point of the solvent in someembodiments.

In some embodiments, a catalyst and/or initiator is added to thesolution to initiate polymerization of the metal-infused organic polymerat a set time and/or times. In some embodiments the solution isvigorously stirred with a stirbar during initiator addition and in someembodiments is continuously stirred vigorously throughout the reaction.In some embodiments, the temperature 19 of the solution is adjustedduring the reacting and in some embodiments is soaked at a specifictemperature for a set amount of time to form a metal-infused organicpolymer 18. In some embodiments, the resulting metal-infused organicpolymer solution is then dried either by heating without a condenserand/or heated under vacuum on a Schlenk line, in a vacuum oven, and/orother means of solvent removal resulting in a metal-infused organicpolymer gel, tar, foam or other dehydrated precursor to an inorganicnano-material. In some embodiments, the metal-infused organic polymer istransferred from its original heating vessel to a substrate usually madeof a heat resistant material (Pyrex glass, stainless steel, fusedsilica, etc.) either before or after solvent removal and in someembodiments, directly after synthesis of the metal-infused organicpolymer.

In an embodiment, the metal-infused polymer precursor 14 and substrateare then put into a heating device such as a kiln, muffles furnace,oven, etc. and heated either in air or other gas with a relatively slowramp of about 40-120° C./hour from about 100° C. to about 300-800° C.and soaked for up to 10 hours or less to produce an inorganicnano-material 18. A resulting inorganic nano-material powder may beobtained by dislodging the solid material from the substrate surface inan embodiment.

In an embodiment, the resulting inorganic nano-material 18 may beamorphous or crystalline with a crystallite size between about 5-60 nm.The resulting inorganic nano-material structure may include micron-sizedparticles with interconnected or individual nano-sized globules, plates,spheres, rods, needles, or other nano-structures with at least onedimension of the particles in the range of about 10-100 nm but sometimeswith larger particles formed from areas with lower organic to inorganicratio.

In an embodiment, the resultant inorganic nano-material 18 may be usedfor a variety of applications including but not limited to an activematerial in a lithium ion battery, a heterogeneous catalyst for watersplitting, super hard scratch resistant coating additive, air filtrationnano-material, drug delivery nano-material and coating additive toincrease hydrophobicity.

In an embodiment, the resultant inorganic nano-material 18 may includeor be nano-LiMn2O4 (SEM images 20A, 20B of same or similar shown inFIGS. 2A and 2B) where such a nano-material may be employed as a cathodematerial for lithium ion batteries in an embodiment. To produce such anano-material according to an embodiment, about 2.2 mmol of lithiumnitrate and about 4.0 mmol of manganese (II) nitrate may be mixed withabout 12.4 mmol of methyl methacrylate, about 0.3 mmol of sodium laurylsulfate, and about equal volume of water to methyl methacrylate and thenheated and stirred in a round bottom flask with condenser at about 60°C. in an oil bath. After about 5 minutes, about 70 µmol of ammoniumpersulfate is added to initiate the formation of the metal-infusedorganic polymer. The temperature of the solution is then allowed toreach about 70° C. for about 1-3 hours to form a metal-infused organicpolymer. In an embodiment, the solution is then dried by first heatingwithout a condenser at 95° C. to remove excess water for about 2-4 hoursuntil the solution becomes a somewhat viscous gel and about 2/5th of theinitial volume. In an embodiment, the resulting metal-infused polymergel may be poured onto a substrate (such stainless steel or fused quartzor others depending on what temperature is needed for the last step) andthen heated under vacuum in a vacuum oven at 95° C. for about 2-4 hoursto form a solid foam. In an embodiment, the metal-infused polymer foamis then put into a kiln in air atmosphere with a ramp of about 40-200°C./hour from about 100° C. to about 550-750° C. and soaked for up to 10hours or less to produce the inorganic nano-material. A resultinginorganic nano-material including nanostructured LiMn2O4 powder may beobtained by dislodging the solid material from the substrate surface.

In an embodiment, the resulting inorganic nano-material may be pure orsubstantially pure LiMn₂O₄ with a crystallite size between about 5-50nm. The resulting inorganic nano-material structure may includemicron-sized particles with interconnected nano-sized globules at thesurface of about 10-200 nm or about 10-100 nm. FIG. 2A includes aclose-up scanning electron microscope (SEM) image 20A of LiMn₂O₄nano-sized globules produced according to an embodiment, and FIG. 2Bincludes a zoomed-out SEM image 20B of the micron structure of theLiMn₂O₄ inorganic nano-material structure.

In an embodiment, the resultant LiMn₂O₄ inorganic nano-material may becrushed into a powder which may be used as the active cathode materialin a lithium ion battery. In an embodiment, slurries made with resultantLiMn₂O₄ inorganic nano-material may achieve mass loadings in the rangeof about 0.1-200 mg/cm² and about 1-40 mg/cm². A resulting electrodeformed with a nano-material according to an embodiment may be chargedand discharged as fast as about 6 minutes versus lithium metal or whenpaired with any anode material of similar kinetic ability in anystandard electrolyte with any standard separator (in addition to thoseelectrolytes and separators which are not standard but allow fast ionicmobility). Further, this structure formed according to an embodiment maybe charged and discharged reversibly for many thousands of cycles due tothe nature of nano-materials according to an electrode that are used inthe electrodes. It should be noted that for nano-LiMn₂O₄, resultingcrystal and particle size has a trade-off of energy density and kineticability; thus a range of sizes are useful for different applications.

In another embodiment, a resultant inorganic nano-material may includeor be a nano-NiFeO3 where such a nano-material may be employed as aheterogeneous water-splitting catalyst. To produce such a nano-materialaccording to an embodiment, about 4.0 mmol of nickel nitrate and about4.0 mmol of iron nitrate may be mixed with about 12.4 mmol of methylmethacrylate, about 0.3 mmol of sodium lauryl sulfate, and about equalvolume of water to methyl methacrylate and then heated and stirred in around bottom flask with a condenser at about 60° C. in an oil bath.After about 5 minutes, about 70 µmol of ammonium persulfate may beadded. The temperature of this solution may be then allowed to reachabout 70° C. for about 1-3 hours to form a metal-infused organicpolymer. In an embodiment, the solution is then dried by first heatingwithout a condenser at 95° C. to remove excess water for about 2-4 hoursuntil the solution becomes a somewhat viscous gel and about 2/5th of theinitial volume.

In an embodiment, the resulting metal-infused polymer gel may be pouredonto a substrate (such stainless steel or fused quartz or othersdepending on what temperature is needed for the last step) and thenheated under vacuum in a vacuum oven at 95° C. for about 2-4 hours toform a solid foam. In an embodiment, the metal-infused polymer foam isthen poured onto a substrate (such as a borosilicate petri dish or steelplate) and then heated in a kiln in air atmosphere with a ramp of about40-200° C./hour from about 100° C. to about 550-750° C. and soaked forup to 10 hours or less to produce the inorganic nano-material. Aresulting inorganic nano-material including a nanostructured FeNiO₃powder may be obtained by dislodging the solid material from thesubstrate surface.

In an embodiment, the resultant inorganic nano-material may be pure orsubstantially pure FeNiO₃ with a crystallite size between about 5-50 nmand about 5-30 nm. The resultant inorganic FeNiO₃ nano-material mayinclude micron-sized particles with interconnected nano-sized globulesat the surface of about 10-100 nm. In an embodiment, the resultantinorganic FeNiO₃ nano-material may be crushed into a powder that may beused as an electrode in a water splitting electrolysis device. Resultingslurries made including resultant inorganic FeNiO₃ nano-material crushedinto a powder may achieve mass loadings in the range of about 0.1-200mg/cm². In an embodiment, an electrode including the resultant inorganicFeNiO₃ nano-material crushed into a powder may split water at a loweroverpotential of around 0.3 mV with high throughput above 10 mA/cm².

As used herein, the singular terms “a,” “an,” and “the” may includeplural referents unless the context clearly dictates otherwise. Thus,for example, reference to an material or embodiments may includemultiple materials or embodiments unless the context clearly dictatesotherwise.

As used herein, the terms “substantially” and “about” are used todescribe and account for small variations. When used in conjunction withan event or circumstance, the terms can refer to instances in which theevent or circumstance occurs precisely as well as instances in which theevent or circumstance occurs to a close approximation. When used inconjunction with a numerical value, the terms can refer to a range ofvariation of less than or equal to ±10% of that numerical value, such asless than or equal to ±5%, less than or equal to ±4%, less than or equalto ±3%, less than or equal to ±2%, less than or equal to ±1%, less thanor equal to ±0.5%, less than or equal to ±0.1%, or less than or equal to±0.05%. For example, “substantially” aligned can refer to a range ofangular variation of less than or equal to ±10°, such as less than orequal to ±5°, less than or equal to ±4°, less than or equal to ±3°, lessthan or equal to ±2°, less than or equal to ±1°, less than or equal to±0.5°, less than or equal to ±0.1°, or less than or equal to ±0.05°

Additionally, amounts, ratios, and other numerical values are sometimespresented herein in a range format. It is to be understood that suchrange format is used for convenience and brevity and should beunderstood flexibly to include numerical values explicitly specified aslimits of a range, but also to include all individual numerical valuesor sub-ranges encompassed within that range as if each numerical valueand sub-range is explicitly specified. For example, a ratio in the rangeof about 1 to about 200 should be understood to include the explicitlyrecited limits of about 1 and about 200, but also to include individualratios such as about 2, about 3, and about 4, and sub-ranges such asabout 10 to about 50, about 20 to about 100, and so forth.

While the disclosure has been described with reference to the specificembodiments thereof, it should be understood by those skilled in the artthat various changes may be made, and equivalents may be substitutedwithout departing from the true spirit and scope of the disclosure asdefined by the appended claim(s). In addition, many modifications may bemade to adapt a particular situation, material, composition of matter,method, operation or operations, to the objective, spirit and scope ofthe disclosure. All such modifications are intended to be within thescope of the claim(s) appended hereto. In particular, while certainmethods may have been described with reference to particular operationsperformed in a particular order, it will be understood that theseoperations may be combined, sub-divided, or reordered to form anequivalent method without departing from the teachings of thedisclosure. Accordingly, unless specifically indicated herein, the orderand grouping of the operations is not a limitation of the disclosure.

What is claimed is:
 1. A method of producing an inorganic nano-materialincluding: forming a metal-infused organic polymer precursor; andheating the formed metal-infused organic polymer precursor to removeorganics and produce an inorganic nano-material.
 2. The method ofproducing an inorganic nano-material of claim 1, including forming ametal-infused organic polymer precursor by a polymer synthesis reactionof at least one organic monomer and at least one metal-containingprecursor.
 3. The method of producing an inorganic nano-material ofclaim 2, wherein at least one organic monomer includes at least oneπ-bond.
 4. The method of producing an inorganic nano-material of claim2, wherein at least one organic monomer includes at least one epoxide.5. The method of producing an inorganic nano-material of claim 2,wherein the synthesis is initiated by at least one initiator molecule.6. The method of producing an inorganic nano-material of claim 2,wherein at least one metal-containing precursor includes at least one ofalkali metal, alkaline earth metal, transition metal, post-transitionmetal, metalloid, lanthanide and actinide.
 7. The method of producing aninorganic nano-material of claim 2, wherein the metal containingprecursor includes at least one of nitrate, hydroxide, carbonate,acetate, and halide.
 8. The method of producing an inorganicnano-material of claim 2, wherein the resulting polymers functionalgroups in the metal-containing precursor are coordinated to the metalfrom the metal-containing precursor forming an interconnectedpolymer/metal-ion matrix.
 9. The method of producing an inorganicnano-material of claim 2, wherein heating the metal-infused organicpolymer precursor includes crystallization of the resulting inorganicnano-material.
 10. A method of producing an inorganic nano-material,including: combining at least one metal containing precursor with atleast one organic monomer to obtain a mixture; and initiating apolymerization reaction of the mixture to form a metal-infused organicpolymer precursor.
 11. The method of producing an inorganicnano-material of claim 10, wherein the metal-infused organic polymerprecursor is heated to remove organics.
 12. The method of producing aninorganic nano-material of claim 11, wherein the resulting structure isan inorganic nano-material.
 13. The method of producing an inorganicnano-material of claim 12, wherein at least one organic monomer includesat least one π-bond.
 14. The method of producing an inorganicnano-material of claim 12, wherein at least one organic monomer includesat least one epoxide.
 15. The method of producing an inorganicnano-material of claim 12, wherein the synthesis is initiated by atleast one initiator molecule.
 16. The method of producing an inorganicnano-material of claim 12, wherein at least one metal-containingprecursor contains at least one of alkali metal, alkaline earth metal,transition metal, post-transition metal, metalloid, lanthanide and/oractinide.
 17. The method of producing an inorganic nano-material ofclaim 12, wherein the metal containing precursor includes at least oneof nitrate, hydroxide, carbonate, acetate, and/or halide.
 18. The methodof producing an inorganic nano-material of claim 12, wherein theresulting polymers functional groups in the metal-containing precursorare coordinated to the metal from the metal-containing precursor formingan interconnected polymer/metal-ion matrix.
 19. The method of producingan inorganic nano-material of claim 11, wherein heating themetal-infused organic polymer precursor includes crystallization of theresulting inorganic nano-material.
 20. A device, component orfabrication which uses the inorganic nano-material described in claim12.